Polymer blends for heat seamable roof sheeting

ABSTRACT

A self-adhering heat seamable sheet material for roofing prepared from an uncured polymeric composition of matter which comprises 100 parts by weight of a polymer blend comprising from about 10 to 95 parts by weight of an polymer selected from the group consisting of semi-crystalline polymers having more than about 2 percent be weight crystallinity and polyolefins having up to about 2 percent by weight crystallinity, which polyolefins are prepared from monomers having at least 2 carbon atoms, and mixtures thereof; and from about 5 to 90 parts by weight of a crystallinity enhancing polymer and mixtures thereof; from about 20 to 300 parts by weight of a filler selected from the group consisting of reinforcing and non-reinforcing materials and mixtures thereof per 100 parts of the polymer blend; and from about 20 to 150 parts by weight of a processing material and mixtures thereof, per 100 parts of the polymer blend. A method for covering a roof comprises the steps of applying layers of self-adhering sheet material prepared from an uncured heat seamable polymeric composition of matter comprising blends of polyolefins, semi-crystalline polyolefins and crystallinity enhancing polymers to the roof being covered; overlapping adjacent edges of the layers; heating the overlapped areas to about the softening point of the sheet material and seaming the overlapped areas under sufficient pressure to provide an acceptable seam strength. For practice of the method, the composition of matter is self-adhering, without the use of an adhesive.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. Ser. No. 07/594,457,filed Oct. 4, 1990, now abandoned.

TECHNICAL FIELD

The present invention relates generally to sheeting material used forcovering roofs. More particularly the sheeting material comprises ablend of an ethylene-propylene-diene terpolymer, referred to herein asEPDM, or ethylene-propylene copolymer, referred to herein as EPR, orother similar olefin type polymers with a crystallinity enhancingpolymer. A method is also provided for covering roofs which includes thestep of employing an uncured, self-adhering EPDM, EPR or similarpolyolefin sheeting material of the present invention.

BACKGROUND OF THE INVENTION

Polymeric roof sheeting is used as single ply roofing membrane forcovering industrial and commercial flat roofs. Such membranes aregenerally applied to the roof surface in vulcanized or cured state.

Because of outstanding weathering resistance and flexibility, cured EPDMbased roof sheeting has been rapidly gaining acceptance. This materialnormally is prepared by vulcanizing uncured composition in the presenceof sulfur or sulfur containing compounds such as mercaptans. Our earlierU.S. Pat. No. 4,803,020 also teaches the use of radiation crosslinkingpromoters in an EPDM sheeting composition which can be cured by ionizingradiation.

Notwithstanding the usefulness of radiation and sulfur curing, adisadvantage with utilizing these elastomers is the lack of adhesion ofEPDM, especially cured EPDM, to itself. This is a serious problembecause in applying EPDM sheets to a roof, it is usually necessary tosplice the cured EPDM sheets together. This splice or seam area issubjected to both short term and long term stresses such as those causedby roof movement, heavy winds, freeze-thaw cycling and thermal cycling.Such stresses may manifest themselves in shear forces or peel forces,i.e., the seam peels back under severe stress conditions or results in apartially open seam (often referred to as a fish-mouth condition) underless severe conditions.

In view of the foregoing problem, it has been necessary to utilize anadhesive to bond the cured EPDM sheets together. As will be evident fromthe above discussion, an adhesive for bonding cured EPDM elastomerroofing sheets together must meet a number of requirements which areextremely difficult to satisfy. Thus, the adhesive must providesufficient peel and adhesive strength to permit the splice formed bybonding the cured EPDM roofing sheets together to resist both short termand long term or stress conditions referred to hereinabove. Moreover,the adhesive must be resistant to oxidation, hydrolysis and chemicalattach from ponded water. Additionally, the adhesive must provide theimportant property often referred to in the adhesive art as "QuickStick". The term "Quick Stick" means the characteristics of two sheetsof material which have been coated with an adhesive composition todevelop virtually immediate adhesive strength when placed in contactwith each other.

Quick Stick is an extremely important property in an adhesive which isutilized to splice cured EPDM elastomer roofing sheets together. Thus,adhesive compositions presently known generally require anywhere fromabout two (2) to about seven (7) days at room temperature (i.e. 22° C.)to attain maximum adhesive strength. At higher ambient temperature, thistime period may be somewhat less, but at minimum it will generally be atleast 24 hours. The conventional procedure for splicing the EPDM roofingsheets together is to make the splice within a relatively short periodof time after the adhesive coating has been applied to each sheet,generally within 30 minutes but often less. Accordingly, the adhesivecomposition must provide sufficient immediate adhesive strength or QuickStick to permit the splice to withstand stresses from winds, movement,handling by installers, etc. until the adhesive achieves its maximumstrength which as indicated will generally take from two (2) to seven(7) days.

Commercial contact adhesives which are conventionally employed forbonding cured EPDM elastomer roofing sheets together generally consistof solutions of neoprene or neoprene-type or butyl or butyl-typepolymers in aromatic or aromatic-aliphatic solvents containing2-butanone often along with tackifying resins. However, such adhesiveshave not proven to be very satisfactory due to their lower thandesirable peel adhesion strengths. Thus, the neoprene or butyl-typeadhesives often provide peel adhesion values at 22° C. of only 1 to 2pounds per linear inch.

Pressure sensitive and contact adhesive compositions containingneutralized, partially neutralized or unneutralized sulfonateelastomers, tackifying resins and organic solvents or organic solventmixtures are known in the prior art as shown by U.S. Pat. No. 3,801,531and 3,867,247.

U.S. Pat. No. 3,801,531 relates to pressure sensitive adhesivecompositions which contain thiouronium derivatives of unsaturatedelastomers or neutralized, partially neutralized or unneutralizedsulfonated elastomers including sulfonated EPDM, tackifying resinsincluding phenol formaldehyde or alkylphenol formaldehyde resins andorganic solvents or organic solvent mixtures including a preferred 90:10mixture of toluene and isopropyl alcohol. However, the patent does notdisclose or suggest the use of alkylphenols or ethoxylated alkylphenolsin such compositions.

U.S. Pat. No. 3,867,247 relates to adhesive contact cements whichcontain neutralized, partially neutralized or unneutralized sulfonatedbutyl elastomers, tackifying resins including phenol formaldehyde oralkylphenol formaldehyde resins and organic solvents or organic solventmixtures including a preferred 90:10 mixture of toluene and isopropylalcohol. However, the patent does not disclose or suggest the use ofalkylphenols or ethoxylated alkylphenols in such compositions.

The adhesive compositions described in the aforementioned patents sufferfrom a significant disadvantage which materially limits their usefulnessas a contact adhesive for bonding cured EPDM elastomer roofing sheetstogether and that is their deficiency in Quick Stick properties.

One such adhesive system for EPDM elastomers that provides good QuickStick is described in U.S. Pat. No. 4,480,012, owned by the Assignee ofrecord herein. Such adhesives comprise a neutralized sulfonated EPDMelastomeric terpolymer; an organic hydrocarbon solvent; a para-alkylatedphenol formaldehyde tackifying resin and an alkylphenol or ethoxylatedalkylphenol. While the use of such adhesive compositions is an effectivemeans of joining and sealing the edges of elastomeric roofing material,if the use of adhesives could be eliminated, the additional labormaterial costs and related hardware necessary to apply the adhesivewould effect a significant cost savings. Moreover, elimination of theneed to cure the material prior to its application to a roof would alsobe advantageous.

Of course, the use of EPDM rubber is not limited to roofing materials.In order to increase use of EPDM and enhance its useful properties it isknown to form blends with other polymers.

U.S. Pat. No. 4,833,194, for instance, discloses blends of crystallineand amorphous polymers, such as EPR type rubbers, which provide uncuredthermoplastic elastomers having good physical properties andweatherability. Typical of such blends are those comprising from about 5to about 45 percent by weight of an amorphous ethylene-propyleneelastomer having less than 65 percent by weight of ethylene; from about55 to about 95 percent by weight of an crystalline ethylene-propyleneelastomer having at least 60 percent by weight of ethylene; and, fromabout 2 to about 35 parts by weight of a crystalline polymer made froman olefin monomer.

U.S. Pat. No. 4,855,362, provides polymer alloys, or blends, whichcomprise a highly unsaturated rubbery polymer, a modified EPDM and atleast one thermoplastic polyolefin. The blends are formed in order totake advantage of the properties of the unsaturated rubbery polymer andthe EPDM, which polymers are difficult to blend. By modifying the EPDMwith N-chlorothio-sulfonamides, they become co-curable with theunsaturated rubbery polymer.

This patent also notes in the Background section that blends ofthermoplastic materials, such as polypropylene, with EPDM have beenfound to possess superior strength, high temperature mechanicalproperties and good compression set. U.S. Pat. No. 4,130,535 disclosesthermoplastic elastomers which comprise 25-75 weight percent ofthermoplastic polyolefin resin, such as polypropylene, and 75-25 weightpercent of monoolefin copolymer rubber, such as EPDM.

SUMMARY OF THE INVENTION

It is thus an object of the present invention to provide polymer blendsfor heat seamable roof sheeting materials that need not be cured.

It is another object of the present invention to provide polymer blendsfor heat seamable roof sheeting materials which eliminate the need for asolvent-based splicing adhesive and the related labor and hardwarenecessary for mixing and application thereof.

It is yet another object of the present invention to provide polymerblends comprising EPDM, EPR, or other similar olefinic type polymers anda crystallinity enhancing polymer which improves the green strength andsplice adhesion of heat seamable roof sheeting materials.

It is still another object of the present invention to provide a methodfor covering roofs which employs polymer blend heat seamable roofsheeting materials which do not require curing and which can be joinedand seamed together at their edges without the use of adhesives.

In general the present invention relates to a self-adhering heatseamable sheet material for roofing prepared from an uncured polymericcomposition of matter comprising 100 parts by weight of a polymer blendcomprising from about 10 to 95 parts by weight of semi-crystallinepolyolefins having more than about 2 percent by weight and polyolefinshaving up to about 2 percent by weight crystallinity, which polyolefinsare prepared from monomers having at least 2 carbon atoms, and mixturesthereof and from about 5 to 90 parts by weight of a crystallinityenhancing polymer; from about 20 to 300 parts by weight of a fillerselected from the group consisting of reinforcing and non-reinforcingmaterials and mixtures thereof per 100 parts of the polymer blend; andfrom about 20 to 150 parts by weight of a processing material andmixtures thereof, per 100 parts of the polymer blend.

A method for covering a roof is also provided and comprises the steps ofapplying layers of self-adhering sheet material prepared from an uncuredheat seamable, polymeric composition of matter comprising blends ofpolyolefins, semi-crystalline polyolefins and crystallinity enhancingpolymers, to the roof being covered; overlapping adjacent edges of thelayers; heating the overlapped areas to about the softening point of thesheet material and seaming the overlapped areas under sufficientpressure to provide an acceptable seam strength the composition ofmatter having sufficient self-adhesion, without the use of an adhesive.

At least one or more of the foregoing objects which shall becomeapparent to those skilled in the art are described in greater detailwith reference to the specification which follows.

PREFERRED EMBODIMENT OF THE INVENTION

As noted hereinabove, the roof sheeting materials of the presentinvention comprise a blend of EPDM, EPR or similar olefin type polymerswith crystallinity enhancing polymers. The term EPDM is used in thesense of its definition as found in ASTM D-1418-85 and is intended tomean a terpolymer of ethylene, propylene and a diene monomer.Illustrative methods for preparing such terpolymers are found in U.S.Pat. No. 3,280,082 the disclosure of which is incorporated herein byreference. The preferred terpolymers contain from about 60 to about 95weight percent ethylene and from about zero to about 12 weight percentof the diene with the balance of the terpolymer being propylene or someother similar olefin type polymer.

The diene monomer utilized in forming the EPDM terpolymer is preferablya non-conjugated diene. Illustrative examples of non-conjugated dieneswhich may be employed are dicyclopentadiene, alkyldicyclopentadiene,1,4-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,4-heptadiene,2-methyl-1,5-hexadiene, cyclooctadiene, 1,4-octadiene,1,7-octadiene,5-ethylidene-2-norbornene,5-n-propylidene-2-norbornene,5-(2-methyl-2-butenyl)-2-norborneneand the like. A typical EPDM is Vistalon® MD-744 (Exxon Chemical Co.) aterpolymer having a Mooney Viscosity (ML/4 at 125° C.) of about 52; anethylene/propylene (E/P) ratio of 61/39 weight percent and 2.7 weightpercent of unsaturation.

Particularly useful and preferred EPDM materials include Royalene® 375(Uniroyal Chemical Co.); and EPsyn® 5508 (Copolymer Rubber & ChemicalCorporation). Royalene® 375 has a Mooney Viscosity (ML/4 at 125° C.) ofabout 50.8; an E/P ratio of 75/25 weight percent and about 2.0 weightpercent of unsaturation (dicyclopentadiene). EPsyn® 5508 has a MooneyViscosity (ML/4 at 125° C.) of about 55.6; and E/P ratio of 73/27 weightpercent and about 3.7 weight percent of unsaturation.

The term EPR is used in the sense of its definition as found in ASTMD-1418 and is intended to mean a copolymer of ethylene and propylene.The preferred copolymers contain from about 60 to 95 weight percentethylene with the balance to total 100 weight percent being propylene. Atypical EPR is Vistalon® 719 (Exxon Chemical Co.) having anethylene/propylene ratio of about 75/25 weight percent.

To be useful as a roofing material in the present invention it ispreferred that the EPDM have at least about 2 weight percentcrystallinity, from the ethylene component; an Mn as measured by GPC ofat least about 30,000 and an Mw, as measured by GPC of at least about100,000. Similarly, the EPR should have at least about 2 weight percentcrystallinity (ethylene); an Mn, as measured by GPC of at least about30,000 and an Mw, as measured by GPC of at least about 100,000. We havefound that the selection of an EPDM or EPR having high crystallinity (atleast 2 percent by weight) and weight average molecular weight(Mw=100,000) is necessary to provide a roofing material which does notrequire curing prior to application, if ever, and which does not requireany type of adhesive, solvent-based or the like, to join and seam thespliced edges.

Also useful as a roofing material in the present invention is acopolymer of ethylene and butene. This particular copolymer has about 82weight percent ethylene with the balance to total 100 weight percentbeing butene. A typical ethylene/butene copolymer is GERS-1085 (UnionCarbide Corporation) having an Mn, as measured by GPC of at least about49,000 and an Mw, as measured by GPC of at least about 221,000. Othersimilar olefinic type polymers can be used to practice this invention.Generally speaking any semi-crystalline polymer having more than about 2percent by weight crystallinity and selected from the group consistingof polyolefins prepared from monomers containing at least 2 carbon atomscan be employed. For purposes of discussion herein, references to EPDM,EPR or similar olefinic polymers is intended to include any of thesemi-crystalline polymers of the present invention.

In addition to the foregoing polyolefins, other polyolefins having up toabout 2 percent by weight crystallinity and prepared from monomershaving at least 2 carbon atoms can be employed. These polyolefins have alower crystallinity than the polyolefins having a crystallinity greaterthan 2 percent and can be utilized in any amount, from 0 parts to 100parts, with the higher crystallinity polyolefins. Again, for ease ofdiscussion, this component of the polymeric composition of matter may bereferred to herein as EPDM, EPR or other polyolefin.

The composition or compound employed to form the roof sheeting materialcomprises a blend of 100 total parts by weight of EPDM, EPR or othersimilar type olefin type polymers, including mixtures of two or moretypes, and a crystallinity enhancing polymer to which is added basicallyfillers and processing oil as well as optionally other componentsincluding curatives, all of which are discussed hereinbelow.

The crystallinity enhancing polymers of the present invention areselected from the group consisting of polyolefin homopolymers, randomcopolymers and block copolymers. Homopolymers include polyethylene andpolypropylene. Random copolymers include poly(ethylene-co-propylene)copolymers. Block copolymers include poly(ethylene-b-octene) andpoly(ethylene-b-butene) copolymers. Mixtures of the foregoing polymerscan be employed or a single polymer can be employed to comprise thepolymeric blend, with the EPDM or EPR polymer comprising from about 10to 95 parts by weight for a total of 100 parts of polymer.

Typical examples of commercially available crystallinity enhancingpolymer additives that can be blended with EPDM, EPR or other similarpolyolefins, materials have been set forth in Table I along with meltingtemperatures and percent of crystallinity.

                  TABLE I                                                         ______________________________________                                        CRYSTALLINITY ENHANCING POLYMERS                                                                      Tm,    % crystal-                                     ETHYLENE HOMOPOLYMERS   °C.                                                                           linity                                         ______________________________________                                        POLYWAX 2000.sup.a      128    89.9                                           POLYWAX 3000.sup.b      121    93.2                                           LDPE 722.sup.c          112    39.1                                           LDPE 132.sup.d          109    27.7                                           LDPE 640.sup.c          113    39.9                                           LDPE 768.sup.f          119    45.8                                           LDPE CG-2523.sup.g      111    53.6                                           HDPE 12065.sup.h        134    66.8                                           HDPE 62013.sup.i        131    61.2                                           PETROLITE E-2020.sup.j  116    85.9                                           POLYPROPYLENE HOMOPOLYMERS                                                    EASTOBOND D-7682-109S.sup.k                                                                           153    4.7                                            A-FAX 500.sup.l         155    5.8                                            ETHYLENE/PROPYLENE      152    35.8                                           COPOLYMERS RLX-020.sup.m                                                      ETHYLENE/OCTENE COPOLYMERS                                                    ATTANE 4003.sup.n       123    36.9                                           ATTANE 4001.sup.o       124    35.0                                           DOWLEX ® 2047A.sup.p                                                                              124    39.8                                           DOWLEX ® 2045.sup.q 124    42.2                                           DOWLEX ® 2038.sup.r 127    53.6                                           DOWLEX ® 2027.sup.s 113    41.5                                           ETHYLENE/BUTENE COPOLYMER                                                                              71    2.3                                            GERS-1085.sup.t                                                               ______________________________________                                         .sup.a High melting polyethylene having a molecular weight of about 2000      (Petrolite)                                                                   .sup.b High melting polyethylene having a molecular weight of about 3000      (Petrolite)                                                                   .sup.c Low density polyethylene resin, density 0.916 (Dow Chemical)           .sup.d Low density polyethylene resin, density 0.919 (Dow Chemical)           .sup.e Low density polyethylene resin, density 0.922 (Dow Chemical)           .sup.f Low density polyethylene resin, density 0.930 (Dow Chemical)           .sup.g Low density polyethylene resin, density 0.923 (Dow Chemical)           .sup.h High density polyethylene resin, density 0.94 (Dow Chemical)           .sup.i High density polyethylene resin, density 0.94 (Dow Chemical)           .sup.j Petroleumderived oxidized hydrocarbon having an acid number of 22      (Petrolite)                                                                   .sup.k Amorphous polypropylene (Eastman Chemical)                             .sup.l Amorphous polypropylene (Himont, USA, Inc.)                            .sup.m Ethylene/propylene copolymer (2% Ethylene) molecular weight about      400,000 (Phillip's Petroleum)                                                 .sup.n Ethyleneoctene copolymer, density 0.905 (Dow Chemical)                 .sup.o Ethyleneoctene copolymer, density 0.912 (Dow Chemical)                 .sup.p Ethyleneoctene copolymer, density 0.917 (Dow Chemical)                 .sup.q Ethyleneoctene copolymer, density 0.920 (Dow Chemical)                 .sup.r Ethyleneoctene copolymer, density 0.935 (Dow Chemical)                 .sup.s Ethyleneoctene copolymer, density 0.941 (Dow Chemical)                 .sup.t Ethylenebutene copolymer (about 82% ethylene), density 0.884 (Unio     Carbide Corporation)                                                     

The crystallinity enhancing polymers are necessary, or of greaterimportance, when the polymer blend comprises increasing amounts ofpolyolefins having less than 2 percent by weight crystallinity. However,even if the polyolefin selected is exclusively one having crystallinitygreater than 2 percent by weight, the presence of a crystallinityenhancing polymer of the present invention provides increased adhesion,as reflected in higher peel and shear adhesion values reportedhereinbelow.

With respect to the filler, suitable fillers are selected from the groupconsisting of reinforcing and non-reinforcing materials, and mixturesthereof, as are customarily added to rubber. Examples include bothinorganic and organic materials such as carbon black, ground coal,calcium carbonate, clay, silica, cryogenically ground rubber and thelike. Generally, preferred fillers include carbon black, ground coal andcryogenically ground rubber.

Carbon black is used in an amount of about 20 parts to about 300 partsper 100 parts of the polymer blend (phr), preferably in an amount ofabout 60 to about 150 phr. The preferred range of carbon black herein(60 to 150 phr) is about equal to the amount of carbon black normallyused in preparing sulfur cured EPDM sheeting. The carbon black usefulherein is any carbon black. Preferred are furnace blacks such as GPF(general purpose furnace), FEF (fast extrusion furnace) and SRF(semi-reinforcing furnace).

The ground coal employed as a filler in the compositions of theinvention is a dry, finely divided black powder derived from a lowvolatile bituminous coal. The ground coal has a particle size rangingfrom a minimum of 0.26 microns to a maximum of 2.55 microns with theaverage particle size of 0.69±0.46 as determined on 50 particles usingTransmission Electron Microscopy. The ground coal produces an aqueousslurry having a pH of about 7.0 when tested in accordance with ASTMD-1512. A preferred ground coal of this type is designated Austin Blackwhich has a specific gravity of 1.22±0.03, an ash content of 4.58% and asulfur content of 0.65%. Austin Black is commercially available fromCoal Fillers, Inc., P.O. Box 1063, Bluefield, Va. Amounts range fromabout 5 to 65 phr with about 15 to 35 being preferred.

Finally, essentially any cryogenically ground rubber may be employed asa filler in the composition of the invention. The preferredcryogenically ground rubbers are cryogenically ground EPDM, butyl,neoprene and the like. A preferred cryogenically ground rubber is acryogenically ground EPDM rubber. The preferred cryogenically groundEPDM rubber is a fine black rubbery powder having a specific gravity of1.129±0.015 and a particle size ranging from about 30 to about 300microns with an average particle size ranging from about 50 to about 80microns. Amounts range from about 5 to 40 phr with about 10 to 25 beingpreferred.

Mixtures of Austin black and cryogenically ground rubber useful hereinmay be utilized as a partial replacement for carbon black. Wheremixtures of these two fillers are employed the relative amounts thereofcan be widely varied; the overall total not exceeding about 60 phr. Theratio of Austin black to cryogenically ground rubber may range from adesired ratio of 2:1 to perhaps even a ratio of 3:1. Amounts thereoffall within the range of amounts normally employed in preparing sulfurcured conventional roof sheeting.

With respect to the processing material, it is included to improve theprocessing behavior of the composition (i.e. reduce mixing time andincrease rate of sheet forming) and includes processing oils, waxes andthe like). The process oil is included in an amount ranging from about20 parts to about 150 parts process oil phr, preferably in an amountranging from about 60 parts to about 135 phr. A preferred processing oilis a paraffinic oil, e.g. Sunpar 2280 which is available from the SunOil Company. Other petroleum derived oils including naphthenic oils arealso useful.

Optional ingredients include, for example, other elastomers (e.g., butylelastomer, neutralized sulfonated EPDM, neutralized sulfonated butyl) inplace of minor amounts of the EPDM, secondary inorganic fillers (e.g.,talc, mica, clay, silicates, whiting) with total secondary fillercontent usually ranging from about 10 to about 150 phr, and conventionalamounts of other conventional agents, such as zinc oxide, stearic acid,antioxidants, antiozonants, flame retardants, and the like.

Regarding curatives, sulfur is preferred in amounts of about 0.3 to 2phr. As noted hereinabove, the roof sheeting compound is not cured priorto application and needed not be cured subsequent thereto. The presenceof sulfur enhances bonding of the seams.

The compounding ingredients can be admixed, utilizing an internal mixer(such as a Banbury mixer), an extruder, and/or a two-roll mill, or othermixers suitable for forming a viscous relatively uniform admixtures.When utilizing a type B Banbury internal mixer, in a preferred mode, thedry or powdery materials such as carbon black are added first followedby the liquid process oil and finally EPDM or other polyolefin andcrystallinity enhancing polymer (this type of mixing can be referred toas an upside-down mixing technique).

The resulting admixture is sheeted to thickness ranging from 5 to 200mils, preferably from 35 to 60 mils, by conventional sheeting methods,for example, milling, calendering or extrusion. Preferably, theadmixture is sheeted to at least 40 gauge (0.040 inches) which is theminimum thickness specified in standards set by the Roofing Council ofthe Rubber Manufacturers Association for non-reinforced black EPDMrubber sheets for use in roofing applications. In many cases, theadmixture is sheeted to 40-45 gauge thickness since this is thethickness for a large percentage of "single-ply" roofing membranes usedcommercially. The sheeting can be cut to desired length and widthdimensions at this time.

The method of the present invention is practiced by utilizing an EPDM orEPR based elastomeric composite sheet material as described herein. Asthe sheet is unrolled over the roof substructure in an otherwiseconventional fashion, the seams of adjacent sheet layers are overlapped.Overlapping (seam width) can vary according to meet the environment aswell as the requirements specified by the architect, building contractoror roofing contractor and thus, does not constitute a limitation of thepresent invention.

Assuming an overlap of several inches, the next step is to apply heatand pressure to the edge area to form the seam. Temperature isconveniently applied from about 80° to 550° C. Generally, the seam area,comprising overlapping edges of adjacent sheets, should be heated toabout the softening point of the sheet material. Numerous techniqueswhich utilize heat and pressure can be used to produce an effective seamas are known to those skilled in the art. Pressure can vary widely froma minimum of about 3 psi up to about 60 psi, typically so long as it isadequate to provide an acceptable seam strength.

In order to demonstrate practice of the present invention, severalcompounds were prepared and subjected to both peel and shear adhesiontests, as will now be set forth in detail. The EPDM polymers selectedincluded Royalene® 375; EPsyn® 5508: and Vistalon® MD-744.Characterization of each of the polymers is presented in Table IIhereinbelow.

                                      TABLE II                                    __________________________________________________________________________    POLYMER CHARACTERIZATION STUDY                                                             Royalene ®                                                                       EPsyn ®                                                                        Vistalon ®                                                                      GERS                                                        375    5508 MD-744                                                                              1085                                           __________________________________________________________________________    ML/4 at 125° C.                                                                     51     55   53    30                                             Ethylene Content, wt %                                                                     76     73   60    82                                             Crystallinity, wt %                                                                        14.6   9.2  <1    2.3                                            Tg, °C. (by DSC)                                                                    -50.6  -43.6                                                                              -56.4 -64.6                                          Tm, °C. (by DSC)                                                                    49.3   40.1 41.6  45, 70                                         Unsaturation, %                                                                            2.0    3.8  2.7   --                                             Type of unsaturation                                                                       DCPD.sup.a                                                                           ENB.sup.b                                                                          ENB.sup.b                                                                           --                                             -- Mn         69,500                                                                               97,800                                                                             73,200                                                                              49,100                                        -- Mw        190,300                                                                              229,100                                                                            360,400                                                                             221,700                                        -- Mn/-- Mw ratio                                                                          2.85   2.34 4.92  4.52                                           __________________________________________________________________________     .sup.a dicyclopentadiene                                                      .sup.b 5ethylidene-2-norbornene                                          

The polymers in Table II, except for Vistalon® MD-744 and GERS-1085(ethylene/butene copolymer), differ from other commercially availableEPDM's (i.e., Royalene® 3180, Royalene® 2859, Vistalon® 2200, etc.), inthat, they are highly crystalline, high ethylene containing polymers.However many of the other polymer properties listed above are similar tomost of the commercially available EPDM terpolymers.

The following examples are submitted for the purpose of furtherillustrating the nature of the present invention and are not to beconsidered as a limitation on the scope thereof. Parts and percentagesare by weight, unless otherwise indicated.

                                      TABLE IIIA                                  __________________________________________________________________________    COMPOSITION OF EPDM AND                                                       CRYSTALLINITY ENHANCING POLYMER BLENDS                                        Example No.                                                                             1*  2   3   4   5   6   7                                           __________________________________________________________________________    Royalene ® 375                                                                      --  --  85  --  60  60  75                                          GERS-1085 --  100 --  --  --  --  --                                          Vistalon ® MD-744                                                                   100 --  --  65  --  --  --                                          Polywax 2000                                                                            --  --  15  --  --  --  --                                          LDPE-768  --  --  --  35  40  --  --                                          Dowlex ® 2027A                                                                      --  --  --  --  --  40  --                                          LDPE-132  --  --  --  --  --  --  25                                          Dowlex ® 2038                                                                       --  --  --  --  --  --  --                                          Dowlex ® 2049A                                                                      --  --  --  --  --  --  --                                          HDPE-12065                                                                              --  --  --  --  --  --  --                                          HDPE-62013                                                                              --  --  --  --  --  --  --                                          HiStr GPF black                                                                         130 128 128 128 128 128 128                                         Sunpar 2280 oil                                                                         88  90  90  90  90  90  90                                          Sulfur    0.90                                                                              --  --  --  --  --  --                                          Austin black                                                                            --  16  16  16  16  16  16                                          Zinc oxide                                                                              4   --  --  --  --  --  --                                          Stearic acid                                                                            1   --  --  --  --  --  --                                          Curing Ingredients                                                                      3.3 --  --  --  --  --  --                                          Total     327.2                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                       __________________________________________________________________________     *Sulfur cured conventional black EPDM membrane                           

                                      TABLE IIIB                                  __________________________________________________________________________    COMPOSITION OF EPDM AND                                                       CRYSTALLINITY ENHANCING POLYMER BLENDS                                        Example No.                                                                             8   9   10  11  12  13  14                                          __________________________________________________________________________    Royalene ® 375                                                                      50  50  50  75  75  75  75                                          GERS-1085 --  --  --  --  --  --  --                                          Vistalon ® MD-744                                                                   --  --  --  --  --  --  --                                          Polywax 2000                                                                            --  --  --  --  --  --  --                                          LDPE-768  --  --  --  25  --  --  --                                          Dowlex ® 2027A                                                                      --  --  --  --  25  --  --                                          LDPE-132  --  --  --  --  --  --  --                                          Dowlex ® 2038                                                                       50  --  --  --  --  --  --                                          Dowlex ® 2049A                                                                      --  50  --  --  --  --  --                                          HDPE-12065                                                                              --  --  50  --  --  25  --                                          HDPE-62013                                                                              --  --  --  --  --  --  25                                          HiStr GPF black                                                                         128 128 128 128 128 128 128                                         Sunpar 2280 oil                                                                         90  90  90  90  90  90  90                                          Sulfur    --  --  --  --  --  --  --                                          Austin black                                                                            16  16  16  16  16  16  16                                          Zinc oxide                                                                              --  --  --  --  --  --  --                                          Stearic acid                                                                            --  --  --  --  --  --  --                                          Total     334.0                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                                                             334.0                                       __________________________________________________________________________

In the examples illustrated in Tables IIIA and B, Example No. 1 provideda sulfur cured black EPDM membrane. The sulfur cured EPDM was preparedutilizing standard rubber mixing techniques and equipment by mixingtogether the following ingredients: 100 parts EPDM terpolymer, 130 phrcarbon black, 88 phr paraffinic process oil, 4 phr zinc oxide, 1 phrstearic acid, 0.9 phr sulfur and 3.3 phr rubber curing ingredients. Theremaining examples Nos. 2-14 comprised only the polymeric material,filler and processing oil to provide compounds that could be sheeted andtested without curing. Complete formulations for each example appear inTables III A and B, hereinabove with all parts given on the basis ofparts per hundred parts of rubber (phr) by weight, unless otherwisespecified.

DETAILED PEEL AND SHEAR ADHESION TEST PROCEDURE

Each of the above rubber compounds was subjected to adhesion testingwhich necessitated the building of test pads comprising 6×6 inch sheetsreinforced by a fiber reinforcement scrim, according to the followingprocedure:

1. A 10×20-inch two roll mill was utilized to prepare a number of6×6-inch sheets of rubber approximately 40 mils in thickness forbuilding adhesion test pads.

2. In order to reinforce the uncured sheets of rubber, a 6×6-inch sheetof PVC treated polyester scrim (10×10 epi cord construction) wasinserted between two 6×6-inch sheets of rubber.

3. The rubber-scrim assembly was covered with a layer of a Mylar filmand placed in the cavity of a metal curing mold (6×6×0.075-inch).

4. The rubber-scrim assembly was then pressed in a Mylar film for aboutfive minutes at about 149° C.

5. Two of the 6×6-inch scrim reinforced rubber pads were seamed togetherusing a hand-held heating gun (Leister). Approximately 15 to 18 poundsforce was supplied by means of a roller such as a standard two-inch widemetal roller. Satisfactory seams (either peel or shear) could be formedusing only 3 to 4 pounds force and the standard two-inch wide rubberroller. The seams were allowed to equilibrate for 24 hours beforetesting.

6. A clicker machine with a one-inch wide die was utilized to prepare anumber of test specimens for seam peel (Type B, 90° peel) and shear(Type A, 180° peel) adhesion testing.

7. Testing machine: Model 1130 Instron Universal Tester--a testingmachine of the constant rate-of-jaw separation type. The machine wasequipped with suitable grips capable of clamping the specimens firmlyand without slippage throughout the tests.

8. The one-inch wide specimens were tested at the rate (both crossheadand chart speed) of two inches per minute using the adhesion test setforth in ASTM D-413 (machine method). Both peel and shear adhesionstrength were determined at room temperature (i.e., 23° C.) as well asoccasionally at 70° and 100° C. Specimens were allowed 15 minutes topreheat prior to testing at elevated temperatures.

9. Adhesion strength is defined as:

    peel adhesion strength (lbs/inch)=pounds force×sample width;

    shear adhesion strength (lbs/square inch)=pounds force×sample width.

Physical properties of each of the rubber compounds were measured andhave been reported in Tables IVA and B hereinbelow. The uncured blackand oil filled membranes featuring EPDM and crystallinity enhancingpolymers exemplified in Tables IVA and B were characterized as harder,higher modulus polymeric compositions having unaged die C tearresistance equivalent to or slightly less than the sulfur cured EPDMmembrane control, Example No. 1.

Adhesion tests with the conventional EPDM material of Example No. 1included the use of a butyl based lap splice adhesive, SA-1065,available from Uniroyal Chemical Co. Peel and shear adhesion atincreasing temperatures for Example No. 1, the sulfur cured control, arereported in Tables VA and B hereinbelow. Unaged peel adhesion and shearadhesion tests conducted with Examples Nos. 2-14, utilized to form thetest pads, are reported in Tables VIA, B-IXA, B, respectively. Crossheadand chart speeds for all adhesion tests were conducted at the rate oftwo inches per minute (ipm).

                  TABLE IVA                                                       ______________________________________                                        UNAGED PHYSICAL PROPERTIES                                                    OF EPDM AND CRYSTALLINITY ENHANCING                                           POLYMER BLENDS IN A HEAT SEAMABLE MEMBRANE                                    Example No. 1      2      3    4    5    6    7                               ______________________________________                                        Stress-Strain                                                                 Properties at 23° C.                                                   100% Modulus, psi                                                                          470   535    300  325  440  --   410                             300% Modulus, psi                                                                         1120   --     655  730  --   --   725                             Tensile at break, psi                                                                     1435   660    870  775  595  225  835                             Elongation at                                                                              420   180    490  325  215   50  380                             break, %                                                                      Low Strain                                                                    Modulus at 23° C.                                                      10% Modulus, psi                                                                           65    140     85  125  150  230  140                             Low Strain                                                                    Modulus at 70° C.                                                      10% Modulus, psi                                                                           45     48     16   43   70   40   60                             Die C                                                                         Tear at 23° C.                                                         Lbs/inch     221   134    175  139  156   76  187                             Shore "A" hardness                                                            Tested at 23° C.                                                                    64     72     61   70   78   77   72                             ______________________________________                                    

                  TABLE IVB                                                       ______________________________________                                        UNAGED PHYSICAL PROPERTIES                                                    OF EPDM AND CRYSTALLINITY ENHANCING                                           POLYMER BLENDS IN A HEAT SEAMABLE MEMBRANE                                    Example No. 8      9      10   11   12   13   14                              ______________________________________                                        Stress-Strain                                                                 Properties at 23° C.                                                   100% Modulus, psi                                                                          760    830   1005 405  1015 580  600                             300% Modulus, psi                                                                         1025   1150   --   660  --   --   --                              Tensile at break, psi                                                                     1080   1185   1030 815  1065 645  745                             Elongation at                                                                              325    320    110 420   120 130  165                             break, %                                                                      Low Strain                                                                    Modulus at 23° C.                                                      10% Modulus, psi                                                                           360    350    800 135   775 240  505                             Low Strain                                                                    Modulus at 70° C.                                                      10% Modulus, psi                                                                           200    180    390 150   310 160  155                             Die C                                                                         Tear at 23° C.                                                         Lbs/inch     265    213    194 206   185 197  204                             Shore "A" hardness                                                            Tested at 23° C.                                                                    87     86     90   75   80   86    83                            ______________________________________                                    

                  TABLE VA                                                        ______________________________________                                        PEEL ADHESION OF                                                              SULFUR CURED EPDM MEMBRANE                                                    Unaged seams                                                                  ______________________________________                                        Membrane seam interply peel adhesion at 23° C.                         lbs/inch        13.00                                                         type of failure adhesive                                                      Membrane seam interply peel adhesion                                          at 50° C.-15 minute preheat at 50° C.                           lbs/inch        7.25                                                          type of failure adhesive                                                      Membrane seam interply peel adhesion                                          at 70° C.-15 minute preheat at 70° C.                           lbs/inch        1.2                                                           type of failure adhesive                                                      Membrane seam interply peel adhesion                                          at 82° C.-15 minute preheat at 82° C.                           lbs/inch        1                                                             type of failure adhesive                                                      Membrane seam interply peel adhesion                                          at 100° C.-15 minute preheat at 100° C.                         lbs/inch        0.85                                                          type of failure adhesive                                                      ______________________________________                                    

                  TABLE VB                                                        ______________________________________                                        SHEAR STRENGTH OF                                                             SULFUR CURED EPDM MEMBRANE                                                    Unaged seams                                                                  ______________________________________                                        Membrane seam shear strength at 23° C.                                 lbs/square inch 27.25                                                         type of failure adhesive                                                      Membrane seam shear strength                                                  at 50° C.-15 minute preheat at 50° C.                           lbs/square inch 18.5                                                          type of failure adhesive                                                      Membrane seam shear strength                                                  at 70° C.-15 minute preheat at 70° C.                           lbs/square inch 11.5                                                          type of failure adhesive                                                      Membrane seam shear strength                                                  at 82° C.-15 minute preheat at 82° C.                           lbs/square inch 9.5                                                           type of failure adhesive                                                      Membrane seam shear strength                                                  at 100° C.-15 minute preheat at 100° C.                         lbs/square inch 7.75                                                          type of failure adhesive                                                      ______________________________________                                    

                                      TABLE VIA                                   __________________________________________________________________________    PEEL ADHESION STUDY OF EPDM                                                   AND CRYSTALLINITY ENHANCING POLYMER BLENDS                                    Example No.  2  3  4  5    6    7                                             __________________________________________________________________________    Peel Adhesion at 23° C.                                                Heat setting #6 (260° C.)                                              Lbs/inch      4.5                                                                               4                                                                                2                                                                              5.5  8    27                                            Type of failure                                                                            (A)                                                                              (A)                                                                              (A)                                                                              (A)  (A)  (A)                                           Heat setting #8 (425° C.)                                              Lbs/inch     16.5                                                                             >41                                                                              >52                                                                              >36  39.5 >58.5                                         Type of failure                                                                            (A)                                                                              (B)                                                                              (B)                                                                              (B)  (A)  (B)                                           Heat setting #10 (550° C.                                              Lbs/inch     15.5                                                                             >35                                                                              >40                                                                              >35  >75.5                                                                              >46                                           Type of failure                                                                            (A)                                                                              (B)                                                                              (B)                                                                              (B)  (B)  (B)                                           __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE VIB                                   __________________________________________________________________________    PEEL ADHESION STUDY OF EPDM                                                   AND CRYSTALLINITY ENHANCING POLYMER BLENDS                                    Example No.  8  9  10 11   12   13   14                                       __________________________________________________________________________    Peel Adhesion at 23° C.                                                Heat setting #6 (260° C.)                                              Lbs/inch     14  12                                                                              3.5                                                                              5.5  14   8    2                                        Type of failure                                                                            (A)                                                                              (A)                                                                              (A)                                                                              (A)  (A)  (A)  (A)                                      Heat setting #8 (425° C.)                                              Lbs/inch     18.5                                                                             >21                                                                              6  >28.5                                                                              22.5 >28.5                                                                              6.5                                      Type of failure                                                                            (A)                                                                              (B)                                                                              (A)                                                                              (B)  (A)  (B)  (A)                                      Heat setting #10 (550° C.)                                             Lbs/inch     23.5                                                                             >24                                                                              12.8                                                                             43   >37.5                                                                              >29.5                                                                              23.5                                     Type of failure                                                                            (A)                                                                              (B)                                                                              (A)                                                                              (A)  (B)  (B)  (A, B)                                   __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE VIIA                                  __________________________________________________________________________    SHEAR STRENGTH OF EPDM AND                                                    CRYSTALLINITY ENHANCING POLYMER BLENDS                                        Example No.  2  3   4   5     6     7                                         __________________________________________________________________________    Shear Strength at 23° C.                                               Heat setting #6 (260° C.)                                              Lbs/square inch                                                                            43.5                                                                             47  67  >99.5 >102  >48.5                                     Type of failure                                                                            (A)                                                                              (A) (A) (B)   (B)   (A)                                       Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            43 >88 >86 >106  >104  >62                                       Type of failure                                                                            (A)                                                                              (B) (B) (B)   (B)   (B)                                       Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            42 >53 >43 >108  >74.5 >58.5                                     Type of failure                                                                            (A)                                                                              (B) (B) (B)   (B)   (B)                                       __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE VIIB                                  __________________________________________________________________________    SHEAR STRENGTH OF EPDM AND CRYSTALLINITY ENHANCING POLYMER BLENDS             Example No.  8     9     10   11  12   13   14                                __________________________________________________________________________    Shear Strength at 23° C.                                               Heat setting #6 (260° C.)                                              Lbs/square inch                                                                            82.5  71.5  23   81  >92.5                                                                              51.5 66                                Type of failure                                                                            (A)   (A)   (A)  (A) (B)  (A)  (A)                               Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            >107.5                                                                              >106  >72.5                                                                              >93 >85  >75.5                                                                              >73                               Type of failure                                                                            (B)   (B)   (B)  (B) (B)  (B)  (B)                               Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            >116.5                                                                              >118  >78  >76 >84.5                                                                              >82  >79                               Type of failure                                                                            (B)   (B)   (B)  (B) (B)  (B)  (B)                               __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE VIIIA                                 __________________________________________________________________________    SHEAR STRENGTH OF EPDM AND                                                    CRYSTALLINITY ENHANCING POLYMER BLENDS                                        Example No.  2    3  4    5    6    7                                         __________________________________________________________________________    Shear Strength at 70° C.                                               Heat setting #6 (260° C.)                                              Lbs/square inch                                                                            30.5 >26                                                                              >56.5                                                                              44.5 23   >31                                       Type of failure                                                                            (A)  (B)                                                                              (B)  (A)  (A)  (B)                                       Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            >37.5                                                                              >30                                                                              >45.5                                                                              >46  >45.5                                                                              >36                                       Type of failure                                                                            (B)  (B)                                                                              (B)  (B)  (B)  (B)                                       Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            37   >36                                                                              >46  >50  >43.5                                                                              >33                                       Type of failure                                                                            (A)  (B)                                                                              (B)  (B)  (B)  (B)                                       __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE VIIIB                                 __________________________________________________________________________    SHEAR STRENGTH OF EPDM                                                        AND CRYSTALLINITY ENHANCING POLYMER BLENDS                                    Example No.  8    9    10 11 12   13   14                                     __________________________________________________________________________    Shear strength at 70° C.                                               Heat setting #6 (260° C.)                                              Lbs/square inch                                                                            >52.5                                                                              70.5  74                                                                               33                                                                              32   24.5 14.5                                   Type of failure                                                                            (B)  (A)  (A)                                                                              (A)                                                                              (A)  (A)  (A)                                    Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            >64  >87.5                                                                              >82                                                                              >45                                                                              >40.5                                                                              >46.5                                                                              >48                                    Type of failure                                                                            (B)  (B)  (B)                                                                              (B)                                                                              (B)  (B)  (B)                                    Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            >73.5                                                                              >84  >89                                                                              >34                                                                              >47  >42.5                                                                              >47                                    Type of failure                                                                            (B)  (B)  (B)                                                                              (B)                                                                              (B)  (B)  (B)                                    __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE IXA                                   __________________________________________________________________________    SHEAR STRENGTH OF EPDM                                                        AND CRYSTALLINITY ENHANCING POLYMER BLENDS                                    Example No.  2  3   4    5    6    7                                          __________________________________________________________________________    Shear Strength at 100° C.                                              Heat setting #6 (260° C.)                                              Lbs/square inch                                                                             5.5                                                                             16  15.5 13   >37  >30.5                                      Type of failure                                                                            (A)                                                                              (A, B)                                                                            (A, B)                                                                             (A)  (B)  (B)                                        Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            27.5                                                                             29.5                                                                              >34  >32.5                                                                              >35  >24                                        Type of failure                                                                            (A)                                                                              (A, B)                                                                            (B)  (B)  (B)  (B)                                        Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            23.5                                                                             >25 >30.5                                                                              >31.5                                                                              >36.5                                                                              >24.5                                      Type of failure                                                                            (A)                                                                              (B) (B)  (B)  (B)  (B)                                        __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                     (B) = Some tearing at interface, followed by rubber separating from the       fabric reinforcement.                                                    

                                      TABLE IXB                                   __________________________________________________________________________    SHEAR STRENGTH OF EPDM                                                        AND CRYSTALLINITY ENHANCING POLYMER BLENDS                                    Example No.  8    9    10   11   12   13   14                                 __________________________________________________________________________    Shear Strength at 100° C.                                              Heat setting #6 (260° C.)                                              Lbs/square inch                                                                            40.5 12.5 51.5 >27.5                                                                              >39  8.5  5.5                                Type of failure                                                                            (A, B)                                                                             (A)  (A)  (B)  (B)  (A)  (A)                                Heat setting #8 (425° C.)                                              Lbs/square inch                                                                            >47.5                                                                              >50.5                                                                              >71  >31  >42.5                                                                              >37.5                                                                              >43.5                              Type of failure                                                                            (B)  (B)  (B)  (B)  (B)  (B)  (B)                                Heat setting #10 (550° C.)                                             Lbs/square inch                                                                            >56  >54  >65.5                                                                              >29  >36.5                                                                              >34.5                                                                              >38                                Type of failure                                                                            (B)  (B)  (B)  (B)  (B)  (B)  (B)                                __________________________________________________________________________     (A) = Failure or separation between plies. (Weld failure)                      (B) = Some tearing at interface, followed by rubber separating from the      fabric reinforcement.                                                    

Lastly, EPsyn® 5508 was evaluated in a formulation comprising 50 partsby weight of EPsyn® 5508; 50 parts by weight of Dowlex® 2027A (copolymerof ethylene and octene); 125 phr carbon black; 16 phr Austin Black and90 phr of Sunpar 2280 process oil, for a total of 331 parts. Physicalproperties and adhesion values were determined as noted above and arereported in Table X. In addition to unaged shear adhesion, several ofthe test samples were aged for seven days at 70° C. prior to testing.Aged shear adhesion at 23° C. and 70° C. is also reported in Table X.

                  TABLE X                                                         ______________________________________                                        PHYSICAL PROPERTIES AND ADHESION                                              VALUES INVOLVING A 50/50 BLEND OF EPSYN ® 5508/                           DOWLEX ® 2027A IN A HEAT SEAMABLE MEMBRANE                                Example No.             15                                                    ______________________________________                                        Unaged Stress-Strain Properties at 73° C.                              Tensile at break, psi   650                                                   Elongation at break, %   90                                                   Unaged Die C Tear at 23° C.                                                                    241                                                   lbs/inch                                                                      Unaged Shore A Hardness at 23° C.                                                               74                                                   tested at 73° C.                                                       Unaged Shear Strength at 23° C.                                        Heat setting #8 (425° C.)                                              Lbs/square inch         >100                                                  Type of Failure         (B)                                                   Unaged Shear Strength at 70° C.                                        Heat setting #8 (425° C.)                                              Lbs/square inch         >53                                                   Type of Failure         (B)                                                   Unaged Shear Strength at 100° C.                                       Heat setting #8 (425° C.)                                              Lbs/square inch         >33                                                   Type of Failure         (B)                                                   Aged Shear Strength at 23° C.*                                         Heat setting #8 (425° C.)                                              Lbs/square inch         >110                                                  Type of Failure         (B)                                                   Aged Shear Strength at 70° C.*                                         Heat setting #8 (425° C.)                                              Lbs/square inch         >69                                                   Type of Failure         (B)                                                   ______________________________________                                         (B) Initial tearing at plyto-ply interface, followed by rubber tearing to     the fabric reinforcement (rubberto-fabric failure)                            *Test samples aged 7 days at 70° C. prior to testing              

Based on the test results in Tables VIA, B-IXA, B, peel adhesion andseam shear strength adhesion values were generally significantly betterthan for the sulfur cured EPDM membrane Example No. 1 (control) therebydemonstrating than the use of EPDM, EPR or other similar olefin typepolymers including ethylene-octene or ethylene-butene copolymers orblends thereof and crystallinity enhancing polymers (e.g., homopolymersof ethylene and propylene, random and block copolymers of ethylene andpropylene, etc.) in black and oil filled compounds using sufficientpressure and heat (usually in the form of hot air) allow the formationof a self-adhering seam without the use of adhesives. Moreover, thesheet materials do not require special curing ingredients nor, do theyrequire that a dusting or release agent be applied to the surface of themembrane followed by autoclave curing.

It is to be understood that the invention is not limited to the specifictype of EPDM exemplified herein or by the disclosure or other typicalEPDM, EPR or other similar olefin type polymers provided herein, theExamples Nos. 2-15 having been provided merely to demonstrate practiceof the subject invention. Those skilled in the art may readily selectother EPDM or EPR as well as other similar polyolefins and crystallinityenhancing polymers. Similarly, the invention is not necessarily limitedto the particular fillers and processing oil exemplified or the amountsthereof.

In order to demonstrate that the compositions of the present inventionexhibit far superior physical properties, including better peel adhesionand shear seam strength, as compared with those disclosed by U.S. Pat.No. 4,833,194, a composition according to the present invention, ExampleNo. 16, was prepared and compared against Examples I and III of U.S.Pat. No. 4,833,194, as Examples No. 17 and 18 respectively. Compositionsfor these three examples are presented in Table XI. Physical propertiesof these three compounds were determined and have been reported in TableXII.

                  TABLE XI                                                        ______________________________________                                        HEAT SEAMABLE EPDM MEMBRANE COMPOSITIONS                                      Example No.     16        17      18                                          ______________________________________                                        Vistalon ® MD-744                                                                         60        --      --                                          HDPE-12065      40        --      --                                          Nordel ® 2760                                                                             --        --      60                                          Nordel ® 2744                                                                             --        25      --                                          Nordel ® 1070                                                                             --        25      20                                          Vistalon ® 707                                                                            --        80      --                                          Petrothene/Na 208                                                                             --        --      15                                          HiStr GPF black 110       --      --                                          HiStr HAF black --        --      15                                          Titanium dioxide                                                                              --        10      --                                          Calcium carbonate                                                                             --        250     125                                         Clay (untreated)                                                                              --        --      25                                          Sunpar 2280 oil 70        --      --                                          Petroleum-based plasticizer.sup.a                                                             --        3       27.5                                        Zinc stearate   --        --      1.0                                         Mark 1500.sup.b --        0.1     0.1                                         AO 2246.sup.c   --        0.1     0.1                                         UV light absorber.sup.d                                                                       --        0.2     0.2                                         TOTAL           280.0     363.4   288.9                                       ______________________________________                                         .sup.a Petrolatum ® SR172 (soft, oily, amorphous substance, used as a     softener, process aid, and internal lubricant (C.P. Hall Company)             .sup.b A phosphite heat stabilizer (Argus Chemical Div., Witco Corp.)         .sup.c Antioxidant 2,2' Methylenebis-(4-methyl-6-tert-butyl-phenol) (R.T.     Vanderbilt)                                                                   .sup.d A Benzotriazole ultraviolet light stabilizerTinuvin ® P            (2(2Hydroxy-5-methyl-phenyl)benzotriazole (CibaGeigy Chemical)           

                  TABLE XII                                                       ______________________________________                                        UNAGED PHYSICAL PROPERTIES                                                    Example No.         16       17     18                                        ______________________________________                                        Stress-Strain Properties at 23° C.                                     Unaged                                                                        100% Modulus, psi   715      235    260                                       300% Modulus, psi   --       430    375                                       Tensile at break, psi                                                                             830      510    650                                       Elongation at break, %                                                                            220      440    630                                       Die C Tear Properties at 23° C.                                        Unaged                                                                        Lbs./inch           261      109    125                                       Shore "A" Hardness   85       76     73                                       Tested at 23° C.                                                       ______________________________________                                    

As clearly evident from Table XII, Example No. 16 provides betterphysical properties than Examples No. 17 or 18.

Next, Examples Nos. 16-18 were subjected to unaged peel adhesion andshear adhesion testing, the results for which have been reported inTables XIII and XIV, respectively.

                  TABLE XIII                                                      ______________________________________                                        PEEL ADHESION COMPARATIVE STUDY                                               Example No.           16     17      18                                       ______________________________________                                        Seam Peel Adhesion at                                                         23° C.-Scrim Reinforced                                                Lbs./inch             13.5   10.6    17.5                                     Type failure          (B)    (B)     (B)                                      Seam Peel Adhesion at 70° C.-Scrim                                     Reinforced-Preheat test specimens for 15                                      minutes before testing                                                        Lbs./inch             10.5   0.4     0.6                                      Type failure          (B)    (A, B)  (A, B)                                   Seam Peel Adhesion at 95° C.-Scrim                                     Reinforced-Preheat test specimens for 15                                      minutes before testing                                                        Lbs./inch             1.5    0.5     0.2                                      Type failure          (B)    (A, B)  (A, B)                                   Heat Gun Setting: No. 9 (peak hot air temperature, 442° C.)            ______________________________________                                         (A) = Weld failure (separation between plies)                                 (B) = Initial tearing at plyto-ply interface, followed by rubber tearing      to the fabric reinforcement (rubberto-fabric failure)                    

                  TABLE XIV                                                       ______________________________________                                        SEAM SHEAR STRENGTH                                                           ADHESION COMPARATIVE STUDY                                                    Example No.            16      17     18                                      ______________________________________                                        Seam Shear Strength Adhesion at                                               23° C.-Scrim Reinforced                                                Lbs./square inch       >105    >38    >71                                     Type failure           (C)     (C)    (C)                                     Seam Shear Strength Adhesion at 70° C.-                                Scrim Reinforced-Preheat test specimens for                                   15 minutes before testing                                                     Lbs./square inch        >60    >23    >35                                     Type failure           (C)     (C)    (C)                                     Seam Shear Strength Adhesion at 95° C.-                                Scrim Reinforced-Preheat test specimens for                                   15 minutes before testing                                                     Lbs./square inch        >47    >17    >24                                     Type failure           (C)     (C)    (C)                                     Heat Gun Setting: No. 9                                                       (Peak hot air temperature, 422° C.)                                    ______________________________________                                         (C) = Necking/breakingscrim reinforced rubber test strip elongated and        broke adjacent to the weld seam                                          

With respect to Table XIII, seam peel adhesion properties at elevatedtemperatures were significantly greater for Example No. 16 than ExamplesNo. 17 or 18. Similarly, seam shear adhesion properties at alltemperatures were better for Examples No. 16 than Examples No. 17 or 18.Accordingly, it should be evident that although U.S. Pat. No. 4,833,194employs blends of amorphous and crystalline EPR's with crystallinepolymers, the compositions of the present invention exhibit propertiesand performance due to the greater crystallinity of the polymer blendcomponents.

In conclusion, it should be clear from the foregoing examples andspecification disclosure that the use of EPDM, EPR or other similarpolyolefins with crystallinity enhancing polymers to prepare sheetmaterial for roofing allows such sheet material to be seamed usingpressure and heat. The seams are self adhering without the use ofadhesives. Moreover, the sheet materials do not require curing. It is tobe understood that the invention is not limited to the specific types ofEPDM and crystallinity enhancing polymers exemplified herein or by thedisclosure of other typical polyolefins and crystallinity enhancingpolymers provided herein, the examples having been provided merely todemonstrate practice of the subject invention. Those skilled in the artmay readily select other polymers than EPDM, EPR and crystallinityenhancing polymers according to the disclosure made hereinabove.Similarly, the invention is not necessarily limited to the particularfillers and processing oil exemplified or the amounts thereof.

Thus, it is believed that any of the variables disclosed herein canreadily be determined and controlled without departing from the scope ofthe invention herein disclosed and described. Moreover, the scope of theinvention shall include all modifications and variations that fallwithin the scope of the attached claims.

What is claimed is:
 1. A self-adhering heat seamable sheet material forroofing prepared from an uncured polymeric composition of mattercomprising:100 parts by weight of a polymer blend comprisingfrom atleast about 25 to 95 parts by weight of a polymer selected from thegroup consisting of polyolefins having less than 1 percent by weightcrystallinity and having an ethylene content of up to about 60 to 61percent by weight, said polyolefins being prepared from monomers havingat least 2 carbon atoms and mixtures thereof; and from about 5 to 75parts by weight of a crystallinity enhancing polymer selected from thegroup consisting of polyethylene and polypropylene homopolymers,poly(ethylene-co-propylene) random copolymers andpoly(ethylene-b-octene) and poly(ethylene-b-butene) block copolymers,said crystallinity enhancing polymer having about 2 up to about 65percent by weight crystallinity; from about 20 to 300 parts by weight ofa filler selected from the group consisting of reinforcing andnon-reinforcing fillers and mixtures thereof per 100 parts of saidpolymer blend; and from about 20 to 150 parts by weight of a processingmaterial selected from the group consisting of paraffinic oils,naphthenic oils and waxes and mixtures thereof, per 100 parts of saidpolymer blend, said sheet material exhibiting a peel adhesion value ofat least 2 pounds/inch and a shear adhesion value of at least 15pounds/square inch, so that seaming is achieved in the absence of anadhesive, said sheet material being devoid of curing ingredients.
 2. Aself-adhering heat seamable sheet material, as set forth in claim 1,wherein said polyolefin having less than 1 percent by weightcrystallinity has an ethylene content of at least about 60 percent byweight and a weight average molecular weight of at least about 100,000.